I'm new here. Hello to everyone.
Sorry to hear of the problem you've had. I wonder if this has come too late for you.
I've had very similar problems like your and I've only solved it a week ago.
My 206 GTi has a hydraulic clutch instead of cables but the principle is the same.
I thought I was going insane trying to solve the problem similar to yours.
Cut a long story short, what gear box oil do you use?
Drain/Flush out the existing oil and fill with Esso/Total 75W/80 GL4 Manual Transmission Fluid (MTF). Free delivery and cheap from MicksGarage online.
I've tried Penrite 75W/80 MTF, Castrol Syntrax 75W/90, Castrol VMX 80 (75W/80),
Fuch Sintofluid 75W/80 MTF. They ALL do not work well. Course feel in gear changes like sand paper. With Penrite oil, I had trouble getting 1st gear and Reverse gear.
The problem occurs most when engine is cold and viscosity of oil is incompatible.
The problem went away when I found an MTF that has similar viscosity to Total 75W/80 MTF. The oil I used was Nulon 75W/80 GL4 MTF (from Australia). It's easy just to get the Esso/Total Oil (I had difficulty sourcing this oil)
Re viscosity, look into detail specification of Esso/Total MTF and the Nulon MTF at 40C and 100C. They are close, that's why my problematic gear change went away.
None of the other MTF oil I tried (even though 75W/80 rating was specified) have viscosity that was compatible to the 206 manual gearbox. Peugeot specified Esso/Total 75w/80 GL4 for a reason.
Good Luck.
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Edited by Avant on 03/10/2014 at 22:34
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